Cable Shield Contact Housing for Stable EMC Under Temperature Cycling
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Solution Overview
Problem
Existing contact systems for electrically conductive cables in distribution housings, particularly those with aluminum braided shields, fail to establish stable connections under temperature cycling stress and often compromise EMC shielding due to complex assembly and gaps in the housing entry, especially in small, high-vibration environments like electric vehicles.
Innovation Solution
A contact system with a shield housing and clamping elements that enclose the cable end, ensuring continuous EMC shielding by clamping the shield between inner and outer sleeves, and using pre-positioned clamping elements for simplified assembly, with optional metal or plastic components for robustness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional radial crimping is used to connect aluminum shielding braid, then assembly is simple, but stable connection under temperature cycling stress cannot be achieved due to oxide layers preventing transverse conductivity
Solution Approach 1:
The patent changes the contacting method from radial crimping to longitudinal compression. The contact element is inserted axially into the cable end and compressed longitudinally against the shielding braid, which allows the contact surface to penetrate through the oxide layers on aluminum wires and establish stable electrical connection, while maintaining assembly simplicity through a single insertion and compression action
2Reliability
If support sleeves with high transverse conductivity are used for crimping, then electrical contact is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of the contact element and the compression mechanism into a single integrated component. The contact element itself performs both the electrical contact function and the compression function through its longitudinal insertion and axial compression, eliminating the need for separate support sleeves and crimping tools, thus reducing device complexity while maintaining reliable electrical contact
3Reliability
If complex assembly procedures are used to ensure EMC shielding, then shielding effectiveness is improved, but ease of operation deteriorates
Solution Approach 1:
The contact element is designed with a pre-formed contact surface that is ready to establish electrical contact with the shielding braid upon insertion. The longitudinal compression action automatically creates the necessary contact pressure and penetration through oxide layers, ensuring reliable EMC shielding connection without requiring complex multi-step assembly procedures, thus improving ease of operation while maintaining shielding effectiveness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides reliable, uninterrupted EMC shielding and stable connections for aluminum braided shields, even in small, high-vibration environments, by simplifying assembly and maintaining electromagnetic integrity at cable entries.
Implementation Method 1
a first contact surface of the inner sleeve contacts the shielding of the electrically conductive cable
Implementation Method 2
at least one clamping element is arranged inside the distribution housing, which clamping element comprises a first clamping jaw and a second clamping jaw for clamping the at least one contact element and end sections of the shield housing shells
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Contact system (1) for electrically contacting a shield (16) of an electrically conductive cable (10) in a distribution housing (30) according to the preamble of claim 1, wherein - at least one cable (10) is passed through a cable inlet (33) of the distribution housing (30) and is electrically connected with its inner conductor (12) to a contact point (48), wherein at least one contact element (20) is arranged in the interior (37) of the housing between the cable inlet (33) and the contact point (48); - a shield housing (40) with shield housing shells (41, 43) is arranged inside the distribution housing (30);- at least one clamping element (50) comprising two clamping jaws (51, 52) for clamping the contact element (20) and end sections (42, 44) of the shield housing shells is arranged within the distribution housing (30), wherein - the shield housing (40) encloses the contact point (48) and the cable end of the cable (10) attached thereto, and wherein end sections (42, 44) of the shield housing shells (41, 43) are each clamped between the contact element (20) and the two clamping jaws (51, 52), so that the shield housing (40) is in contact with the contact element (20) or the shield (16) and is pressed against it at least partially enclosing it, thereby making at least indirect contact with the shield (16) of the cable (10).